Method of forming a semiconductor structure

ABSTRACT

A method of forming a semiconductor structure comprises forming a first layer of silicon and then forming a second, silicon germanium, layer adjacent the silicon layer. A thin third layer of silicon is then formed adjacent the second layer. A gate structure is then formed upon the third layer of silicon using convention Complementary Metal Oxide Semiconductor processes. Trenches are then formed into the second layer and the structure is then exposed to a thermal gaseous chemical etchant, for example heated hydrochloric acid. The etchant removes the silicon germanium, thereby forming a Silicon-On-Nothing structure. Thereafter, conventional CMOS processing techniques are applied to complete the structure as a Metal Oxide Semiconductor Field Effect Transistor, including the formation of spacer walls from silicon nitride, the silicon nitride also filling a cavity formed beneath the third layer of silicon by removal of the silicon germanium.

FIELD OF THE INVENTION

This invention relates to a method of forming a semiconductor structure of the type, for example, comprising a layer of dielectric material disposed between two layers of semiconductor material.

BACKGROUND OF THE INVENTION

In the field of semiconductor device fabrication, it is known to perform isotropic lateral etching of a sacrificial layer when manufacturing certain semiconductor devices. For example, a so-called “Silicon-On-Nothing” (SON) Metal Oxide Semiconductor Field Effect Transistor (MOSFET) makes use of a Silicon-Germanium (SiGe) sacrificial layer to disposed a thin silicon layer beneath a gate stack that serves as an active region for the MOSFET, the use of the thin silicon active region providing significant device performance advantages. As part of the fabrication process of the MOSFET, the Si—Ge sacrificial layer is laterally etched and replaced with an oxide buffer layer.

In order to etch the Si—Ge sacrificial layer, either a wet chemical etch solution or an isotropic plasma etching technique is employed in a downstream or remote plasma tool, such as a Chemical Downstream Etcher (CDE) or a Decoupled Plasma Source (DPS)].

Whilst the use of isotropic plasma etching results in a very selective etch due to the electrochemical potential difference between silicon and silicon-germanium, it is difficult to control and cannot be readily monitored in-situ. Further, plasma etching for lateral etches does not currently provide adequate selectivity since the selectivity is lost when the silicon-germanium etch is completed or the etch endpoints is reached. For some applications, an additional masking layer of either resist, or a hard mask of oxide, may also have to be provided to enable plasma etching to be used.

In relation to the use of wet chemical etching solutions, these also suffer from a number of disadvantages. Indeed, whilst also selective, use of such solutions can result in mechanical damage to extremely small and delicate thin features of a device being etched. Additionally, progress of a wet chemical etch is difficult to monitor as no directly measurable parameter is available, for example by means of optical emission. Further, use of wet chemical etching solutions for lateral etching can be limited to the wetting of the etching solution in nano-sized features. Also, like DPS, wet chemical etching is also difficult to control and suffers from a loss of selectivity at Si—Ge endpoints.

STATEMENT OF INVENTION

According to the present invention, there is provided a method of forming a semiconductor structure as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

At least one embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a foundation strata of 3 layers of semiconductor material;

FIG. 2 is a schematic diagram the foundation of FIG. 1 supplemented by an insulating layer and an electrode layer for formation of a gate stack;

FIG. 3 is a schematic diagram of the gate stack formed from the structure of FIG. 2;

FIG. 4 is a schematic diagram of trenches formed in the structure of FIG. 3 in accordance with an embodiment of the invention;

FIG. 5 is a schematic diagram of a sacrificial layer removed from the structure of FIG. 4 in accordance with the embodiment of the invention; and

FIG. 6 is a schematic diagram of a partially completed device according to the embodiment of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

Throughout the following description identical reference numerals will be used to identify like parts.

Referring to FIG. 1, a Metal Oxide Semiconductor Field Effect (MOSFET) transistor device 5 is formed by firstly growing a silicon substrate 10, constituting a first layer of semiconductor material, in accordance with a known Complementary Metal Oxide Semiconductor (CMOS) processing technique. Using a known suitable epitaxy deposition technique, a second, Silicon-Germanium, layer 12 is then grown on the silicon substrate 10 to a thickness of 30 nm. Thereafter a third, silicon, layer 14 is grown on the Silicon-Germanium layer 12 to a thickness of 20 nm. Alternatively, the first layer of semiconductor material is formed from a different material to the third layer of semiconductor material.

Turning to FIG. 2, a gate stack is then formed using a conventional CMOS processing technique. In this example, a dielectric material, for example silicon dioxide (SiO₂), or typically a material with a dielectric constant greater than that of silicon, known as a high-K material, is then deposited as a gate insulator layer 16, on the silicon layer 14. The gate insulator layer 16 is grown to a thickness sufficient to constitute a high quality dielectric layer. Typically, the gate insulator layer 16 is grown to a thickness of between about 15 and 30 Angstroms depending on the dielectric constant of the material and the technological application.

Thereafter, polysilicon (PolySi) or a metal is deposited over the gate insulator layer 16 to form a gate electrode layer 18 and serve as a gate electrode.

The gate insulator layer 16 and the gate electrode layer 18 are then subjected to an initial etch (FIG. 3) to form a gate stack 20, the gate insulator layer 16 sharing the profile of the gate electrode layer 18. Consequently, an upper surface 22 of the layer of silicon 14 is exposed.

Using conventional CMOS processing techniques (FIG. 4), a photoresist pattern (not shown) is used to protect an active area, typically using a mask that is a size revision of a mask used to form the active area.

Alternatively, other masking materials can be used to form the mask, depending upon a best sequence of fabrication integration, such as use of silicon nitride (SiN) to form a hard mask on the gate stack 20, since SiN has high resistance to fluorine and chlorine species etchants.

Using the photoresist pattern, a pair of trenches 24 is etched into areas of the layer of silicon 14 to be used for a source region and a drain region, respectively. The pair of trenches 24 is etched using a standard Reactive Ion Etching (RIE) process, thereby creating an opening in the layer of silicon 14 so as to expose the Si—Ge layer 12. In order to control the etching process, Optical Emission Spectroscopy (OES) signals can provide an ability to detect an end of the RIE process, known as endpoint detection. The etching of the trenches 24 is halted once the trenches have penetrated the Si—Ge layer 12, or when the trenches 24 begin to penetrate the substrate 10.

The device 5, usually formed as part of a semiconductor wafer (not shown), is then placed in a thermal reactor, for example, a single wafer epitaxy deposition tool or a Rapid Thermal Process (RTP) tool. Inside the tool, the Si—Ge layer 12 is exposed to a thermal gaseous chemical etchant, for example gaseous hydrochloric acid. The hydrochloric acid is maintained in a gaseous phase through heating, the gaseous hydrochloric acid being maintained at a temperature of between about 600° C. and 900° C., for example between about 700° C. and 800° C., such as between about 750° C. and 800° C. Additionally, the pressure within the tool is lower than atmospheric pressure, typically 0.1 to 0.5 ATM (100 mTorr to 500 mTorr) and can be used with an inert dilutant gas, such as argon or helium. Use of dilutants and the reduced pressure serves to improve control of the ambient gas (the gaseous hydrochloric acid diluted with the dilutant gas) and uniformity of the etchant gas flow and reduces the reactant flows to 100 to 200 sccm for a typical single wafer process tool.

In the gaseous phase, the chemical etchant etches isotropically and provides high selectively in order of more than 100:1 in favour of silicon germanium. For practical purposes, the selectivity can be considered to be almost infinite.

Although heated gaseous hydrochloric acid has been used in this example, the skilled person will appreciate that other thermal gaseous etchants can be used depending upon the material to be etched, for example chlorine (Cl₂) Boron Chloride (BCl₃) or other suitable halogen gases.

Referring to FIG. 5, the thermal gaseous chemical etchant isotropically etches the Si—Ge layer 12 laterally until substantially the entire Si—Ge layer 12 has been removed, and in this respect OES endpoints can again be used to control progress of the etchant, leaving a cavity 26 beneath the layer of silicon 14, i.e. between the layer of silicon 14 and the substrate 10.

Once the Silicon-Germanium has been removed from beneath a part of the layer of silicon 14 below the gate stack 20, i.e. the part of the layer of silicon 14 that will serve as a channel for the device 5, when in use, the photoresist is removed using a standard in-situ oxidization step and/or a separate so-called “plasma ash” process.

Thereafter, another conventional CMOS processing technique is employed to deposit a sidewall spacer 28 of silicon nitride (Si₃N₄) 30 adjacent both sides of the gate stack 20. The silicon nitride 30 also enters the cavity 26 via the pair of trenches 24 and fills the cavity 26 with the silicon nitride spacer material 30 during the deposition of the sidewall spacers 28. Alternatively, the cavity can be filled by means of a separate deposition stage to the creation of the sidewall spacers 28. The separate deposition stage can be used to fill the cavity 26 beneath the gate stack 20 with a different material to silicon nitride, for example a high emissivity (high-k) dielectric to improve electrical isolation of the active region from the bulk substrate or a combination of dielectric and conductor (poly-silicon) to form a bottom gate electrode creating a multi-gate (“gate-all-around”) structure. As a further alternative, the cavity 26 can be left empty.

Subsequently (and not shown in FIG. 6), source and drain regions are respectively formed either side of the gate stack 20 in the layer of silicon 14 using a conventional CMOS processing technique. Indeed, the rest of the device 5 is completed in accordance with the conventional CMOS processing techniques and so for the sake of clarity and conciseness of description will not be described further herein.

From the above example, the skilled person will appreciate that the thickness of the Si—Ge layer 12 can be altered in order to vary the volume of the cavity 26.

Although not described thus far, the above described transistor device can constitute a bit in a volatile memory unit, for example a Random Access Memory (RAM), such as a Static RAM, sharing the active layer of silicon 12 with a number of like structured transistors. In fact, the skilled person should understand that the etching process by which the sacrificial Si—Ge layer 12 is removed is not limited to the formation of MOSFETs, or even transistors, but rather is a general process that can be used for other applications where isotropic lateral selective etching is required, for example in the formation of Silicon-On-Nothing (SON) structures or other three-dimensional device structures using bulk substrates. Indeed, the above-described thermal gaseous chemical etching process is applicable, for example, to creation of any nano-scale device, such as Micro Electro-Mechanical Systems devices comprising very thin suspended silicon structures.

It is thus possible to provide a method of forming a semiconductor structure that provides greater etch selectivity than existing etching techniques for fabricating silicon on nothing devices. Additionally, the tools required to create the structure are simpler in nature to existing tools used to remove a sacrificial layer, such as the silicon germanium layer 12. Further, process parameters, such as time, temperature, gas flow and pressure, are more controllable than parameters used in relation to the existing tools for removing the sacrificial layer. Consequently, process complexity is reduced, resulting in a significant manufacturing cost saving. 

1. A method of forming a semiconductor structure, the method comprising the steps of: disposing a first layer of semiconductor material; disposing a second layer of semiconductor material adjacent the first layer of semiconductor material; disposing a third layer of semiconductor material adjacent the second layer of semiconductor material; disposing a gate insulator layer over the third layer; disposing a gate electrode layer over the gate insulator layer; forming a pair of trenches through at least the third layer to expose the second layer of semiconductor material for access by an etchant thereto, the pair of trenches disposed on opposite sides of the gate insulator layer and the gate electrode layer; exposing the second layer of semiconductor material to a thermal gaseous chemical etchant, the thermal gaseous etchant laterally and isotropically etching the second layer of semiconductor material so as to form a cavity between the first and third layers of semiconductor material, wherein the second layer of semiconductor material is formed from a different material to the first and third layers of semiconductor material; and depositing a sidewall spacer material to form a sidewall on the gate insulator and the gate electrode, the sidewall spacer material depositing into the cavity.
 2. A method as claimed in claim 1, wherein the thermal gaseous etchant is selective in favour of etching the second layer of semiconductor material.
 3. A method as claimed in claim 1, wherein the thermal gaseous etchant is at a temperature of between about 700 degree C. and 800 degree C.
 4. A method as claimed in claim 1, wherein the thermal gaseous etchant is at a temperature of between about 600 degree C. and 900 degree C.
 5. A method as claimed in claim 1, wherein the thermal gaseous etchant is exposed to the second layer of semiconductor material under a predetermined pressure.
 6. A method as claimed in claim 5, wherein the predetermined pressure is between about 10 mTorr and about 500 mTorr.
 7. A method as claimed in claim 6, wherein the predetermined pressure is between about 50 mTorr and about 100 mTorr.
 8. A method as claimed in claim 1, wherein the first layer of semiconductor material is formed from a different material to the third layer of semiconductor material.
 9. A method as claimed in claim 1, wherein the first layer of semiconductor material is a silicon layer.
 10. A method as claimed in claim 1, wherein the third layer of semiconductor material is silicon.
 11. A method as claimed in claim 1, wherein the second layer of semiconductor material is a sacrificial layer.
 12. A method as claimed in claim 1, wherein the second layer of semiconductor material is a Silicon-Germanium layer.
 13. A method as claimed in claim 1, wherein the thermal gaseous chemical etchant is gaseous Hydrochloric Acid.
 14. A method as claimed in claim 1, wherein the semiconductor structure is a transistor.
 15. A method as claimed in claim 14, wherein the transistor is a Field Effect Transistor.
 16. A method as claimed in claim 14, wherein the transistor is a Complementary Metal Oxide Semiconductor transistor.
 17. A method as claimed in claim 1, wherein the first layer of semiconductor material is a substrate.
 18. A method as claimed in claim 1, depositing the sidewall space material fills the cavity with a dielectric material.
 19. A method as claimed in claim 1, wherein thermal gaseous chemical etchant is mixed with a dilutant gas.
 20. A method as claimed in claim 19, the dilutant gas is an inert gas.
 21. A method of forming a semiconductor structure, the method comprising: depositing a second layer of semiconductor material adjacent a major surface of a first layer of semiconductor material; growing a third layer of semiconductor material adjacent a major surface of the second layer of semiconductor material opposite the major surface of the first layer of semiconductor material; depositing a gate insulator layer over the third layer; depositing a gate electrode layer over the gate insulator layer; forming a gate stack from the gate insulator layer and the gate electrode layer, the gate stack having a gate stack profile; forming a pair of trenches through at least the third layer to expose the second layer of semiconductor material for access by an etchant thereto, the pair of trenches disposed on opposite sides of the gate stack at edges of the gate stack profile; exposing the second layer of semiconductor material to a thermal gaseous chemical etchant, the thermal gaseous etchant laterally and isotropically etching the second layer of semiconductor material so as to form a cavity between the first and third layers of semiconductor material; and depositing a sidewall spacer material to form a sidewall on the gate stack, the sidewall spacer material depositing into the cavity. 